TEC TRU UV Coater Operating And Safety Manual Download

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TRU UV Coater

OPERATING AND SAFETY MANUAL

For the following Models:

TRUV-16D, TRUV-21D, TRUV-30A

TRUVF-16D, TRUVF-21D, TRUVF-30A

S/N_____________________

TEC Lighting, Inc.

555 Vanguard Way

Brea, Ca. 92821

www.teclighting.com

Phone (714) 529-5068 Fax (714) 529-0344

Summary of Contents for TRU UV Coater

Page 1: ...ND SAFETY MANUAL For the following Models TRUV 16D TRUV 21D TRUV 30A TRUVF 16D TRUVF 21D TRUVF 30A S N_____________________ TEC Lighting Inc 555 Vanguard Way Brea Ca 92821 www teclighting com Phone 71...

Page 2: ...due to improvements or changes to the feeder In the event of major changes to the feeder TEC Lighting will update and issue a new edition of this manual Disclaimer This manual goes through the entire...

Page 3: ...neath rubber and metering roller to prevent buildup of contamination dirt coating grease paper dust which can cause damage to paint and all moving parts MONTHLY Monitor position of conveyor belt to en...

Page 4: ...own Process 42 47 14 0 UV Coater Clean up process 48 50 15 0 Fast Stop Process 51 54 16 0 E Stop Process 55 17 0 Error Message 55 18 0 Restart Process 56 19 0 Coater Restart Process 57 20 0 Sheet Coun...

Page 5: ...eyewear 8 DO NOT make modifications to the machine without written agreement from TEC Lighting 9 DO NOT leave tools equipment or any material lying on the machine 10 Keep metal container near by the...

Page 6: ...stand and follow all safety guidelines and operating instruction Any Machine with rotating rollers and UV lighting can be dangerous Be sure all safety guards are in place and fully secured before oper...

Page 7: ...between the two rollers when the metering roller adjustment knobs apply pressure The sheets then exit the roller coater and are transported with a conveyor system to the IR and UV lamps Production sp...

Page 8: ...stem Control panel Touch screen In feed table Auto or Manual Deep pile vacuum cup feeder Safety covers Lamp housing with mercury vapor arc lamp and elliptical reflector IR Lamp housing with 3 IR lamp...

Page 9: ...MENT Conveyor belts Exhaust tubing Reflector inserts Capacitors UV Lamp see below IR Lamp see below UV COATER SYSTEM The UV Coater assembly motor and motor drive and related components are warranted f...

Page 10: ...and evaluate before shipping any replacement Warranty replacement parts will ship via ground If customer requires replacement parts sooner customer needs to provide the shipping account number All pa...

Page 11: ...e K W 3 200 K W Primary Input Voltage 208 220 240vac 60Hz 1ph Total System Running Amperage 32A no feeder 40A with feeder Service Disconnect 40A no feeder 50A with feeder Conveyor Belt Part No BELT 42...

Page 12: ...e K W 4 200 K W Primary Input Voltage 208 220 240vac 60Hz 1ph Total System Running Amperage 37A no feeder 46A with feeder Service Disconnect 50A no feeder 60A with feeder Conveyor Belt Part No BELT 37...

Page 13: ...W P I Wattage K W 6 000 K W Primary Input Voltage 208 220 240vac 60Hz 3ph Total System Running Amperage 50A no feeder 55A with feeder Service Disconnect 60A Conveyor Belt Part No BELT 380 UV Lamp TR3...

Page 14: ...Screen Main control panel for operation 5 Emergency Stop Complete shutdown blower remains on 6 Feeder Table Up Raises feeder table 7 Feeder Table Down Lower the feeder table 8 Feeder Auto Manual Auto...

Page 15: ...sheet metal bolts are not loosened from transport vibration Use proper tools for tightening E Electrical power is ready for hook up refer to Section 4 0 4 2 F Make sure your work area is clean and rea...

Page 16: ...e Catch Tray station 2 Insert the LEFT side of the catch tray insertion pin into its holding block 3 Remove the RIGHT side holding block Place the block on the insertion pin as shown SECTION 6 2 CATCH...

Page 17: ...17 4 Re attach the holding block into position and secure with screws 5 Set the supporting legs into position Make sure the legs are straight 6 Set the height adjustment per your requirement...

Page 18: ...aper guide and thru the catch tray slotted hole 8 On the back side of the catch tray secure with flat washer and hex nut 9 To lock the handle push downward To open lift up the handle Adjustment to the...

Page 19: ...er open box and inspect the lamp for shipping damages Clean UV lamp glass body with TEC Lighting cleaning solution TECAL70 Handle the UV lamp carefully 1 Open the electrical panel door 2 Lift open top...

Page 20: ...ll on connected internal wiring 5 Lift up the extrusion and place on work bench 6 Rotate the assembly to expose the reflector mirror NOTE Extra cleaning of the reflector mirror maybe required use TEC...

Page 21: ...se into supporting block NOTE Please be very careful not to add pressure on the UV Lamp FRAGILE 8 Re attach the supporting block and secure with wing nuts Check the opposite end and make sure it s sec...

Page 22: ...lamp into its compartment Note There are two guide pins for proper alignment Make sure the extrusion is fully seated and secured with guide pins Guide Pins 10 Connect the male and female insulated con...

Page 23: ...ment and I R lamps 1 Open the I R lamp compartment as per Section 7 0 par 1 3 11 Reset UV panel make sure the fan lead wires don t get pinched during closer Unlatch top cover panel carefully lower int...

Page 24: ...ck all terminal connections heat shield alignment and I R lamps 4 Reset I R panel make sure the fan lead wires don t get pinched during closer Unlatch top cover panel carefully lower into position and...

Page 25: ...ction SECTION 9 0 FEEDER PRE SET UP TRU Coater has two electrical connection to energize the feeder They are located on the outer panel below the UV Coater rollers 1 Move the feeder in front of the UV...

Page 26: ...tches Each notch should line up with carriage thumb screw Secure into position with the thumb screw 6 Each roller guide should be placed on the green belt as shown in the picture above left side To ap...

Page 27: ...required depends on your sheet size 9 Place your stack of papers on the leveling boards Make sure all corners are squared and evenly stacked 10 Loosen the locking handle on the support guide rails bo...

Page 28: ...ders are equipped with 2 sets of the paper weight assemblies Customer has the option to set up 1 or 2 paper weight stations 12 One station set up in the center as shown 13 Two stations set up evenly a...

Page 29: ...ation 220VAC 240VAC 1 Make sure the main power is in the OFF position Insert your power line thru the electrical port hole 2 Connect your power line to the terminal block as shown above TRUV 21 is 1 p...

Page 30: ...Open UV Coating compartment door 2 Connect the brass fitting hose to the blue or orange tubing Make sure the fitting is secure Open the fluid pump head and insert the black hose as shown Orange tubin...

Page 31: ...ert the larger clear tubing fluid return 7 Make sure the ratchet hose clamp is OPEN This clamp is used only when exchanging UV coating or during clean up 4 Close the pump head check the tubing for any...

Page 32: ...both tubing s are secured 10 Double check all tubing hoses are secure Make necessary adjustments to secure the UV Coating container Close the cabinet door 9 Open the plexi glass cover The blue and ora...

Page 33: ...ols for the belt and I R are set to zero 0 1 Turn ON your main power at the service disconnect 2 Turn ON the system disconnect switch WARNING High Voltage is engage thru the system 3 After turning on...

Page 34: ...o the ON position Metering Impression 6 Open the UV Coating compartment Engage the Metering roller turn the knob counterclockwise Engage the Impression rollers turn the knob counterclockwise The Meter...

Page 35: ...TER CLUTCH icon switch to the ON position NOTE The rollers will start turning 10 Press the UV FLUID PUMP icon switch to the ON position 11 Engage the DOCTOR BLADE Refer to the decal for directions As...

Page 36: ...UV Coater is a hand fed system you are now ready to start your production run Continue this process at paragraph 22 12 Carefully move the feeder into its position Do not pinch the power cable nor hit...

Page 37: ...hen limits are reached 13 Set the feeder to Manual control Turn and hold the selector switch to TABLE UP position Your feeder table will rise up Release the switch the feeder table will stop 14 Slowly...

Page 38: ...Make sure all suction cups that are over the paper are OPENED Pushing downward on the plastic housing will open the air suction 16 Set the paper weight assemblies into position Refer to Section 9 par...

Page 39: ...ivate the feeder table to rise automatically during the process The sensor lever has a steel ball to support the paper from improper feeding 17 Set the Feeder control to AUTO position The table will r...

Page 40: ...tor prevents double sheeting Refer to Trouble Shouting Solution Guide Section XXX 19 Press the FEEDER AIR PUMP icon switch to the ON position WARNING THIS FEEDER HAS ROTATING ROLLERS AND CAN CAUSE SER...

Page 41: ...r 2 side panels as show below WARNING THE COATER AND FEEDER HAS ROTATING ROLLERS AND CAN CAUSE SERIOUS INJURY Refer to section 9 paragraph 4 the paper roller guides and strap Adjustments maybe require...

Page 42: ...42 23 Run approximately 5 10 sheets If your system is equipped with a feeder turn OFF the Feeder Air Pump Check the sheets quality finish...

Page 43: ...on refer to Trouble Shooting Solution Guide Section XXX 26 At this point you have now completed the start up process It s very important you stay by the system while monitoring the paper input from th...

Page 44: ...or without Feeder control Please read carefully throughout this process understanding if the feeder applies or does not apply to the process 1 Turn OFF Feeder Air Pump 2 Set the Feeder and the I R in...

Page 45: ...Pump 5 Allow time for the UV Coating to flow off the rollers Increasing the Coater Speed will help this process NO UV COATING 6 After UV Coating is completely gone set the Coating Speed to zero 0 Not...

Page 46: ...en the plastic cover is opened an error message will display on the touch screen This is a Warning message to let you known a safety interlock door is open 9 Disengage the doctor blade Note If you hav...

Page 47: ...n roller turn the knob clockwise METERING IMPRESSION 12 Press the error message icon The message should disappear 11 Carefully close the plexi glass cover 13 Remove the unwanted stack of paper from th...

Page 48: ...t down process For roller cleanup continue to Section 14 UV Coater Cleanup Process 15 Turn OFF System icon switch 14 Before turning off the system the UV Lamp must be off Refer to paragraph 3 16 Turn...

Page 49: ...CAN CAUSE SERIOUS INJURY Never leave the rollers engaged when not in operational This will cause a flat spot on the rubber roller and affect the coating quality Note Before cleaning allow the excesse...

Page 50: ...an cloth and wipe off all UV Coating Clean all 3 rollers Rubber Metering and Impression 5 Cleaning the Doctor Blade with EXTREME CAUTION Apply a small amount of UV wash to a clean cloth and wipe behin...

Page 51: ...of UV wash to a clean cloth and wipe the lower drain pan 7 Open the UV Coating compartment Open the UV pump head to relief pressure from the tubing Close the cabinet door You have now completed the U...

Page 52: ...e than 20 minutes when not in operation This will cause a flat spot on the rubber roller and affect coating quality The Fast Stop switch is located on the touch screen Highlighted in yellow Fast Stop...

Page 53: ...ss cover Note After opening the plexi glass cove an error message will display on the touch screen This is a Warning message to let you know a safety interlock door is open 2 Disengage the doctor blad...

Page 54: ...Open The red icon will disappears 7 Set the Coater and Feeder Speed to zero 0 8 Press the Coater Clutch icon switch to the ON position 4 Clean up any excess UV Coating that may have spilled on the fee...

Page 55: ...ition If your system has a Feeder system continue to step 10 If your UV Coater is a OFF LINE system you are now ready to start your production run 10 Press the Feeder Air Pump icon switch to the ON po...

Page 56: ...con it will disappear after all doors and panels are closed The following panels are interlock activated Exhaust blower panel Gear motor door Main electrical panel door UV Coater plexi glass cover see...

Page 57: ...eration This will cause a flat spot on the rubber roller and affect coating quality 1 After shutdown remove or make necessary fixes 2 If repair takes more than 20 minutes disengage the metering impres...

Page 58: ...quality 1 After shutdown remove or make necessary fixes 2 If repair takes more than 20 minutes disengage the metering impression roller and the doctor blade Refer to section 13 paragraphs 9 10 3 Refe...

Page 59: ...ts ran during your production cycle To reset the counter meter touch the sheet counter icon green box and the number will reset to zero To return to main screen touch the RETURN icon switch 3 The touc...

Page 60: ...n not in operation This will cause a flat spot on the rubber roller and affect coating quality 1 Turn OFF main power 2 Open plexi glass cover and unlatch hinges carefully remove the cover SECTION 23 0...

Page 61: ...61 6 Remove the socket screw for the roller gear guard 7 Remove the roller gear guard 8 Remove the 2 socket screws for bearing holding block Repeat this step on the opposite side of the roller...

Page 62: ...r roller inspect the rubber roller for any shipping damages Check the bearing and roller gear 11 Carefully insert the rubber roller into its supporting holder Make sure the rubber roller is not scratc...

Page 63: ...UV Coating drainage port as shown in picture above far right 14 Closed both side panel doors re attach plexi glass cover and lower the Fluid spouts refer to paragraph 2 3 and 4 You have completed the...

Page 64: ...stall the new conveyor belt over the vacuum panel and rollers reconnecting the junction point refer to paragraph 2 Re insert the new insert pin Make sure all connecting loops are jointed SECTION 26 0...

Page 65: ...enter of the roller 7 Slowly engage the take up bearing assembly both ends turning counter clock wise 8 Set both adjustment rods approx to the same dimension 9 Check the belt flatness no curves Make a...

Page 66: ...If the conveyor belt moves off center moves to the left make adjustments to the right side of the take up bearing If the belt moves to the right make adjustment to the left side of the take up bearin...

Page 67: ...TER DOCTOR BLADE HAS SHARP EDGES AND CAN CAUSE SERIOUS INJURY 1 Turn OFF main power 2 Your UV Coater maybe equip with the following features Feed table loosen the thumb screws and remove the table Con...

Page 68: ...l be helpful to hold one end of the bracket CAUTION THE DOCTOR BLADE HAS SHARP EDGES 5 Carefully lift and remove the doctor blade assembly CAUTION THE DOCTOR BLADE HAS SHARP EDGE 6 Carefully set the d...

Page 69: ...HAS SHARP EDGE 9 If required remove the aluminum plate and clean any excess UV Coating from both mounting plates 10 If removed replace the aluminum plate and mounting screws insert the doctor blade ba...

Page 70: ...ctor blade with no pins needs to be set at 10mm as shown above The doctor blade with slots needs to line up with the pins on the holder Secure both holders with mounting screws NOTE You may receive a...

Page 71: ...15 Inspect the doctor blade it must be level with the impression roller Engage the doctor blade with a soft touch to the impression roller this will help you to see if any misalignment with the blade...

Page 72: ...oller 16 TR16MR Metering roller 21 TR21MR Metering roller 30 TR30MR Impression bottom roller 16 TR16IBR Impression bottom roller 21 TR21IBR Impression bottom roller 30 TR30IBR Doctor Blade 16 TR16DB D...

Page 73: ...2mm Hose fitting XC 037 16 Plexi glass cover assembly 40 5007 21 Plexi glass cover assembly 40 5005 30 Plexi glass cover assembly 40 5006 White poly Sprocket gear Chain drive GR 224 Belt drive GR 224A...

Page 74: ...bearing parts Bearing BRG 051 2 Retaining Ring 20mm RTNG 014 2 Impression roller bearing parts Gray steel Sprocket gear GR 226 Bearing BRG 051 2 Retaining Ring 20mm RTNG 014 2 Retaining Ring 25mm RTNG...

Page 75: ...n assembly TRUV21 TR21EXT Extrusion assembly TRUV30 TR30EXT 16 UV LAMP TR16UVL 21 UV LAMP TR21UVL 30 UV LAMP TR30UVL 16 Reflector liner set TR16RL 21 Reflector liner set TR21RL 30 Reflector liner set...

Page 76: ...76 I R Cap Base XC 035 16 I R LAMP TR16IR 21 I R LAMP TR21IR 30 I R LAMP TR30IR 16 I R Reflector shield set 40 0067 21 I R Reflector shield set 40 0066 30 I R Reflector shield set 40 0065...

Page 77: ...r Belt BELT 424 30 Conveyor Belt BELT 428 16 Conveyor exit roller TR16CER 21 Conveyor exit roller TR21CER 30 Conveyor exit roller TR30CER 16 Conveyor rubber roller TR16CRR 21 Conveyor rubber roller TR...

Page 78: ...0 days The grease type should be SKF brand NLGI LGEP LGHP or equiv The lubricant oil should be Hydraulic oil DTE 25 or equiv CAUTION Lubricating oil and grease are hazardous materials please review MS...

Page 79: ...rotective 1VT70 Disposable Gloves S 14179L 100 per box Wipe Cloth 560027 2 bags Lamp Cleaning Solution M313 Cotton Gloves S 7892M 2 pairs Metric Allen Wrench 505 0308 TEC Lighting Inc 555 Vanguard Way...

Page 80: ...veyor belt within minutes glue then heat No major disassembly required Order number CBHK 220vac is required Contact Your Sales Representative For More Information TEC Lighting Inc 555 Vanguard Way Bre...

Page 81: ...ds and odors Inline system is equipped with high performance 745 CFM inline fan pack with RC 4 8 premium grade of collie carbon Easy to install with the UV Coater Operating voltage 120vac 60hz TEC Lig...

Page 82: ...___ Date operational ________________ Contact names person who were trained ________________________________________ ________________________________ _______________________________________ __________...

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